Modular sloped roof solar mounting system

ABSTRACT

A mounting system for supporting a plurality of photovoltaic modules on a sloped support surface, such as a sloped roof, is disclosed herein. The mounting system may include one or more support surface attachment devices, each support surface attachment device configured to attach one or more photovoltaic modules to a support surface; and one or more module coupling devices, each module coupling device configured to couple a plurality of photovoltaic modules to one another.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a divisional of U.S. patent application Ser. No. 15/817,671,entitled “Modular Sloped Roof Solar Mounting System”, filed on Nov. 20,2017; and U.S. Nonprovisional patent application Ser. No. 15/817,671 isa divisional of U.S. patent application Ser. No. 14/541,127, entitled“Modular Sloped Roof Solar Mounting System”, filed on Nov. 13, 2014, nowU.S. Pat. No. 9,825,581; which claims priority to U.S. ProvisionalPatent Application No. 61/904,049, entitled “Modular Sloped Roof SolarMounting System”, filed on Nov. 14, 2013, and further claims priority toU.S. Provisional Patent Application No. 62/014,054, entitled “ModularSloped Roof Mounting System”, filed on Jun. 18, 2014, the disclosure ofeach of which is hereby incorporated by reference as if set forth intheir entirety herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable.

INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK

Not Applicable.

FIELD OF THE INVENTION

The field of the present invention generally relates to mounting systemsand, more particularly, to support assemblies and mounting systems formounting photovoltaic modules or panels on sloped support surfaces suchas, for example, sloped building rooftops, or the like.

BACKGROUND OF THE INVENTION

There is a need for a sloped roof solar mounting system that attaches torafters or roof supporting members, avoids using rails or struts, and isuniversal.

Solar panels must be secured to the roof and underlying structure todisperse wind and snow loads into the building structure. Although somemounting systems that avoid using rails attach to the roof decking, theydo not attach to the roof rafters because the spacing of rafters isdifferent than the length of modules.

Rails and struts are long extrusions or roll-formed strips that must becut to length, use excess material, are costly to manufacture and highin shipping cost. Therefore, a mounting system avoiding the use of railsor struts is desired.

There is a need for the system to mount to any solar module on themarket, giving installers the flexibility to choose the module of theirchoice, rather than be required to buy a module with a custom profilerail to accommodate the mounting system.

BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

Accordingly, the present invention is directed to a modular sloped roofsolar mounting system that substantially obviates one or more problemsresulting from the limitations and deficiencies of the related art.

In accordance with one or more embodiments of the present invention,there is provided a support surface attachment device configured toattach one or more photovoltaic modules to a support surface. Thesupport surface attachment device includes a lower support memberconfigured to be attached to a support surface; and a clamp assemblyconfigured to engage one or more photovoltaic modules, the clampassembly configured to be fixed in place relative to the lower supportmember. In these one or more embodiments, the clamp assembly is capableof being selectively positioned along a length of the lower supportmember prior to being fixed in place relative to the lower supportmember so as to permit adjustability when the one or more photovoltaicmodules are being attached to the support surface.

In a further embodiment of the present invention, the clamp assembly ofthe support surface attachment device comprises a lower clamp member andan upper clamp member, the upper clamp member connected to the lowerclamp member by a threaded fastening device.

In yet a further embodiment, the lower clamp member of the clampassembly comprises a pair of ledges extending outwardly from oppositelydisposed outer side surfaces of the lower clamp member, one of the pairof ledges comprising a groove disposed therein for receiving a portionof a skirt mounting member.

In still a further embodiment, the support surface attachment devicefurther comprises an upper support member, the upper support memberconfigured to operate as a handle for rotating the clamp assemblyrelative to the lower support member, and thereby lock the clampassembly in place relative to the lower support member.

In yet a further embodiment, the threaded fastening device furtherconnects the clamp assembly to the upper support member.

In still a further embodiment, the support surface attachment devicefurther comprises a cam-type locking mechanism that locks the clampassembly in place relative to the lower support member without the useof tools.

In accordance with one or more other embodiments of the presentinvention, there is provided a coupling device configured to attach oneor more photovoltaic modules to one or more other photovoltaic modules.The coupling device includes a lower coupling member including at leastone ledge extending outwardly from a side surface of the lower couplingmember; and an upper coupling member including at least one flangeportion extending outwardly from the upper coupling member, the uppercoupling member being adjustably connected to the lower coupling memberby at least one fastening device. In these one or more otherembodiments, the one or more photovoltaic modules and the one or moreother photovoltaic modules are configured to be clamped between the atleast one ledge of the lower coupling member and the at least one flangeportion of the upper coupling member.

In a further embodiment of the present invention, the lower couplingmember further includes a pair of generally vertical walls havingoppositely disposed outer side surfaces, and wherein the at least oneledge comprises a pair of ledges extending outwardly from the oppositelydisposed outer side surfaces of the generally vertical walls.

In accordance with yet one or more other embodiments of the presentinvention, there is provided a support surface attachment deviceconfigured to attach one or more photovoltaic modules to a supportsurface. The support surface attachment device includes a rotatable basemember, the rotatable base member being pivotal about a centralrotational axis, the rotatable base member configured to be attached toa support surface; and a clamp assembly configured to engage one or morephotovoltaic modules, the clamp assembly coupled to the rotatable basemember. In these one or more other embodiments, the clamp assembly iscapable of being selectively positioned along a circumferential path ofthe rotatable base member prior to the rotatable base member being fixedin place relative to the support surface so as to permit adjustabilitywhen the one or more photovoltaic modules are being attached to thesupport surface.

In a further embodiment of the present invention, the clamp assembly ofthe support surface attachment device comprises a lower clamp member andan upper clamp member, the upper clamp member connected to the lowerclamp member by a first threaded fastening member.

In yet a further embodiment, the support surface attachment devicefurther comprises a second threaded fastening member, the secondthreaded fastening member coupling the clamp assembly to the rotatablebase member.

In still a further embodiment, the support surface attachment devicefurther comprises a flashing member having a fastener apertureconfigured to receive a fastener for attaching the rotatable base memberand the flashing member to the support surface, the fastener aperturebeing disposed through a raised position of the flashing member so thatwater is prevented from passing through the fastener aperture.

In accordance with still one or more other embodiments of the presentinvention, there is provided a mounting system for supporting aplurality of photovoltaic modules on a support surface. The mountingsystem includes a support surface attachment device, the support surfaceattachment device configured to attach one or more photovoltaic modulesto a support surface, the support surface attachment device including aclamp assembly, and the clamp assembly including at least one upwardlytapered ledge extending from an outer side of the clamp assembly. Inthese one or more other embodiments, the at least one upwardly taperedledge is configured to function as a spring for applying a compressiveforce against the one or more photovoltaic modules so as to securelyretain the one or more photovoltaic modules in the clamp assembly.

In a further embodiment of the present invention, the clamp assembly iscapable of being attached anywhere along a peripheral edge of the one ormore photovoltaic modules.

In yet a further embodiment, the mounting system further comprises amodule coupling device, the module coupling device configured to attachone or more photovoltaic modules to one or more other photovoltaicmodules.

In yet a further embodiment, the mounting system does not include amounting rail that is configured to span multiple photovoltaic modules.

In accordance with yet one or more other embodiments of the presentinvention, there is provided a mounting system for supporting aplurality of photovoltaic modules on a support surface. The mountingsystem includes a support surface attachment device, the support surfaceattachment device configured to attach one or more photovoltaic modulesto a support surface, the support surface attachment device including aclamp assembly, the clamp assembly including a lower clamp member and anupper clamp member, the lower clamp member having an outwardly extendingcomponent extending from an outer side of the lower clamp member; askirt mounting member, the skirt mounting member comprising a firstplurality of protrusions; and a skirt member, the skirt membercomprising a second plurality of protrusions, the second plurality ofprotrusions on the skirt member configured to matingly engage the firstplurality of protrusions on the skirt mounting member.

In a further embodiment of the present invention, the skirt mountingmember comprises a downwardly extending portion configured to engagewith a groove in the outwardly extending component of the lower clampmember of the clamp assembly; and wherein the skirt member is configuredto engage with the upper clamp member of the clamp assembly.

It is to be understood that the foregoing general description and thefollowing detailed description of the present invention are merelyexemplary and explanatory in nature. As such, the foregoing generaldescription and the following detailed description of the inventionshould not be construed to limit the scope of the appended claims in anysense.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention will now be described, by way of example, with referenceto the accompanying drawings, in which:

FIG. 1 is a perspective view of a support surface attachment device of aphotovoltaic mounting system, according to a first illustrativeembodiment of the invention, wherein a clamp assembly of the supportsurface attachment device is in a disengaged position with respect tothe lower support member, and the support surface attachment device isshown installed on a roof;

FIG. 2 is a perspective view of the support surface attachment device ofFIG. 1, wherein the clamp assembly of the support surface attachmentdevice is in an engaged position with respect to a lower support member;

FIG. 3 is an end view of the support surface attachment device of FIG.1, wherein the clamp assembly of the support surface attachment deviceis in an engaged position with respect to the lower support member;

FIG. 4 is a side view of the support surface attachment device of FIG.1, wherein the clamp assembly of the support surface attachment deviceis in an engaged position with respect to the lower support member;

FIG. 5 is a side perspective view of a clamp assembly of the supportsurface attachment device of FIGS. 3 and 4;

FIG. 6 is a side view of the clamp assembly of FIG. 5;

FIG. 7 is an end view of the clamp assembly of FIG. 5;

FIG. 8 is a perspective view of an upper clamp member of the clampassembly of FIG. 5;

FIG. 9 is an exploded perspective view of the clamp assembly of FIG. 5;

FIG. 10 is a perspective view of a lower clamp member of the clampassembly of FIG. 5;

FIG. 11 is an end perspective view of a coupling device of the mountingsystem, according to the illustrative embodiment of the invention;

FIG. 12 is a top view of the coupling device of FIG. 11;

FIG. 13 is a side view of the coupling device of FIG. 11;

FIG. 14 is an end view of the coupling device of FIG. 11;

FIG. 15 is a perspective view of an upper coupling member of thecoupling device of FIG. 11;

FIG. 16 is a perspective view of a lower coupling member of the couplingdevice of FIG. 11;

FIG. 17 is a lower support member of the support surface attachmentdevice of FIGS. 3 and 4;

FIG. 18 is an exploded perspective view of the coupling device of FIG.11;

FIG. 19 is a side view of the support surface attachment device of FIGS.3 and 4, wherein the support surface attachment device is shownillustrated with a lower skirt member and a photovoltaic module attachedthereto;

FIG. 20 is a front end view of the support surface attachment device andlower skirt member of FIG. 19;

FIG. 21 is a perspective view of the lower skirt member and skirtmounting bracket of FIG. 20;

FIG. 22 is an end view of the lower skirt member and skirt mountingbracket of FIG. 21;

FIG. 23 is an end view of the lower skirt member of FIG. 21;

FIG. 24 is an end view of the skirt mounting bracket of FIG. 21;

FIG. 25 is a perspective view of the illustrative mounting systemdescribed herein being used to secure an array of photovoltaic modulesto a sloped roof;

FIG. 26 is a side perspective view of a bracket assembly of the mountingsystem, according to the illustrative embodiment of the invention;

FIG. 27 is a side view of the bracket assembly of FIG. 26;

FIG. 28 is a perspective view of another support surface attachmentdevice of a photovoltaic mounting system, according to a secondillustrative embodiment of the invention, wherein the support surfaceattachment device comprises a rotatable disc member for east-west andnorth-south adjustment;

FIG. 29 is a top view of the support surface attachment device of FIG.28;

FIG. 30 is an end view of the support surface attachment device of FIG.28;

FIG. 31 is a side view of the support surface attachment device of FIG.28;

FIG. 32 is a longitudinal sectional view of the support surfaceattachment device of FIG. 28, which is generally cut along thecutting-plane line A-A in FIG. 30;

FIG. 33 is a side partial exploded perspective view of the supportsurface attachment device of FIG. 28;

FIG. 34 is a perspective view of a disc member of the support surfaceattachment device of FIG. 28;

FIG. 35 is a top view of the disc member of FIG. 34;

FIG. 36 is a bottom view of the disc member of FIG. 34;

FIG. 37 is a sectional view of the disc member of FIG. 34, which isgenerally cut along the cutting-plane line B-B in FIG. 35;

FIG. 38 is a side view of the disc member of FIG. 34;

FIG. 39 is an end view of the disc member of FIG. 34;

FIG. 40 is a perspective view of a flashing member of the supportsurface attachment device of FIG. 28;

FIG. 41 is a top view of the flashing member of FIG. 40;

FIG. 42 is a side view of the flashing member of FIG. 40;

FIG. 43 is an end view of the flashing member of FIG. 40;

FIG. 44 is a sectional view of the flashing member of FIG. 40, which isgenerally cut along the cutting-plane line C-C in FIG. 43;

FIG. 45 is a perspective view of the threaded fastener member of theclamp assembly of FIG. 9; and

FIG. 46 is a partial, enlarged perspective view of the head of thethreaded fastener member of FIG. 45 (Detail “A”).

Throughout the figures, the same parts are always denoted using the samereference characters so that, as a general rule, they will only bedescribed once.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

It will be apparent to those skilled in the art, that is, to those whohave knowledge or experience in this area of technology, that many usesand design variations are possible for the improved mounting systems andmethods disclosed herein. The following detailed discussion of variousalternative and preferred embodiments will illustrate the generalprinciples of the invention with regard to the specific application ofrooftop mounted photovoltaic (PV) modules that are in the form ofrectangular-shaped panels. Other embodiments suitable for otherapplications will be apparent to those skilled in the art given thebenefit of this disclosure such as for example, PV modules havingdifferent shapes.

With initial reference to the perspective view FIG. 25, the constituentcomponents of an illustrative photovoltaic mounting system will begenerally described. FIG. 25 illustrates a roof-mounted photovoltaicsystem or array according to an embodiment of the present invention. Theillustrated photovoltaic system or array includes an array of solarpanels or PV modules 114 mounted to a pitched or sloped support surfacein the form of a building rooftop 98 by a mounting system. In FIG. 25,there are two rows of PV modules 114 illustrated for exemplary purposes,each of the two rows having three (3) PV modules 114 disposed therein.The illustrated mounting system includes a plurality of support surfaceattachment devices 100 that secure the array of PV modules 114 to thebuilding rooftop 98. As shown in FIG. 25, the five (5) support surfaceattachment devices 100 disposed in the middle of the PV array bridge thetwo rows of PV modules 114. The PV array illustrated in FIG. 25 has eachof the rectangular-shaped PV modules 114 oriented in a landscapeorientation, that is, with the longest axis of the PV modules 114extending in a lateral or side-to-side direction which is typically theeast-west direction. It is noted, however, that the PV modules 114 canalternatively be oriented by the support surface attachment devices 114in a portrait orientation, that is, with the longest axis of the PVmodules 114 extending in a forward-rearward direction which is typicallythe south-north direction. With reference again to FIG. 25, it can beseen that the illustrated mounting system also includes a plurality ofcoupling devices 60 that rigidly fasten a plurality of PV modules 114 toone another. As shown in FIG. 25, the coupling devices 60 connect thecorners of adjacent PV modules 114 together. While not visible in FIG.25, the mounting system may further include a plurality of bracketassemblies 120 for securing one or more respective electrical assembliesto the underside of one or more PV modules 114.

As shown in the perspective view of FIG. 25, in a first embodiment, eachillustrated PV module 114 is supported by a plurality of the supportsurface attachment devices 100. Each support surface attachment device100 is connected to at least one of the PV modules 114 but some of theillustrated support surface attachment devices 100 are connected to morethan one of the PV modules 114 (e.g., the five (5) support surfaceattachment devices 100 connected between the two (2) of PV modules 114).The illustrated PV modules 114 are secured to the support surfaceattachment devices 100 (as described in more detail hereinafter) buteach of the support surface attachment devices 100 is not directlysecured to any of the other support surface attachment devices 100(e.g., there is no rail member connecting one support surface attachmentdevice 100 to another support surface attachment device 100). It isnoted that non-load bearing components, such as skirt members, and thelike can also be supported by the support surface attachment devices 100as described in more detail hereinafter. Advantageously, the mountingsystem described herein is capable of being used with PV modules 114 ofany width and length without requiring customization or modification tothe support surface attachment devices 100 or the PV modules 114. Thus,a common support surface attachment device 100 can be used in manyapplications to mount many different models of PV modules 114. In theillustrated embodiment of FIG. 25, each support surface attachmentdevice 100 is secured to a respective one of the roof rafters 116 bymeans of a structural mounting screw 102 (e.g., refer to FIGS. 3 and 4).In one or more embodiments, the structural mounting screw 102 may beself-drilling so as not to require any predrilled holes in the roof.

Now, turning initially to FIGS. 3-7, the components of the supportsurface attachment devices 100 (i.e., the mounting assemblies 100)illustrated in FIG. 25 will be described. As shown in these figures, ina first embodiment, each support surface attachment device 100 generallycomprises a lower support member 42 configured to be attached to asupport surface (e.g., the building rooftop 98 of FIG. 25); and a clampassembly 50 configured to engage one or more PV modules 114, the clampassembly 50 is configured to be locked in place relative to the lowersupport member 42 without the use of tools. In particular, as bestillustrated in FIGS. 1 and 2, when the upper tubular support member 30is turned approximately 90 degrees clockwise by a user thereof (i.e., aPV system installer), the clamp assembly 50 is capable of being lockedin place relative to the lower support member 42 without the use of atool (e.g., wrench, etc.). Because the clamp assembly 50 can be lockedin place anywhere along the length of the lower support member 42, thenecessary mounting location of the PV modules 114 can be easilyaccommodated after the lower support member 42 has been fixedly attachedto the roof rafter 116 by means of the structural mounting screw 102. Assuch, it is not necessary for the lower support member 42 to beprecisely located along the length of the roof rafter 116 because thesupport surface attachment device 100 described herein advantageouslyaffords generous adjustability in the south-north installation directionand/or east-west installation direction. Also, the support surfaceattachment devices 100 can also be flexibly located in the east-westdirection on the building rooftop 98 such that they correspond with thespacing of the roof rafters 116 because the support surface attachmentdevices 100 can be mounted virtually anywhere along the length (i.e.,east-west direction) of the PV modules 114.

As shown in FIG. 17, the lower support member 42 generally comprises abase portion 44, a ledge or shelf portion elevated above the baseportion 44, and opposed flange portions 46 disposed above the ledge orshelf portion. As illustrated in this figure, the opposed flangeportions 46 define a locking mechanism slot 48 for receiving the lockingcap member 38 of the clamp assembly 50 disposed therein. The locking capmember 38, which operates as a cam-like locking mechanism, locks theclamp assembly 50 in place relative to the lower support member 42 whenthe handle-like tubular member 30 is turned approximately 90 degreesclockwise by a user thereof (i.e., a PV system installer). As shown inFIG. 17, the ledge or shelf portion of the lower support member 42,which is elevated above the base portion 44 thereof, comprises anaperture 49 disposed therein for accommodating the passage of a tool fordriving the structural mounting screw 102 into the roof rafter 116(e.g., a socket wrench for driving the structural mounting screw 102into the roof rafter 116). While not explicitly visible in theperspective view of FIG. 17, the base portion 44 of the lower supportmember 42 comprises a fastener aperture disposed therethrough foraccommodating the structural mounting screw 102. This fastener aperturein the base portion 44 of the lower support member 42 is disposeddirectly below, and is generally aligned with, the aperture 49.Referring to FIG. 20, it can be seen that a sealing washer 104 may beprovided between the head of the structural mounting screw 102 and thebase portion 44 of the lower support member 42 for adding redundancy tothe waterproofing of the support surface attachment device 100. As shownin FIG. 17, the lower support member 42 may have a generally trapezoidalshape. The lower support member 42 provides north-south mountingflexibility and/or east-west mounting flexibility. In one exemplaryembodiment, the lower support member 42 may be formed from aluminum, thestructural mounting screw 102 may be formed from stainless steel, andthe sealing washer 104 may be formed from stainless steel with anethylene propylene diene monomer (EPDM) sealing ring.

With reference to FIGS. 1-4, it can be seen that the support surfaceattachment device 100 may further include a plate-like flashing member96. The flashing member 96 is configured to be slipped underneath ashingle course so that a northern portion of the flashing member 96 isdisposed underneath the shingle course and a top surface of a southernportion of the flashing member 96 is exposed for accommodating themounting of the lower support member 42 on the top thereof (e.g., seeFIG. 1). The flashing member 96 helps to maintain the integrity of thebuilding roof 98 by preventing roof leaks. In one exemplary embodiment,the flashing member 96 may be formed from aluminum, and may include anethylene propylene diene monomer (EPDM) grommet for superiorwaterproofing around the aperture that receives the structural mountingscrew 102. In one or more embodiments, the structural mounting screw 102attaches through the sealing washer 104, the lower support member 42,the EPDM grommet, and the flashing member 96 so as to securely affix themounting assembly 100 to a roof rafter 116 in a waterproof manner. Also,in one exemplary embodiment, the upper and lower clamp members 10, 20and the upper support member 30 may be formed from aluminum, and thethreaded fastening device 32 (e.g., bolt) may be formed from stainlesssteel.

Next, with particular reference to FIGS. 5-7 and 9, it can be seen thatthe illustrative clamp assembly 50 of the support surface attachmentdevice 100 generally comprises an upper clamp member 10, a lower clampmember 20, and an upper tubular support member 30 (which operates as ahandle or arm for engaging the clamp assembly 50 with the lower supportmember 42). As shown in FIGS. 5-7 and 9, the upper clamp member 10 isconnected to the lower clamp member 20 and to the upper tubular supportmember 30 by a threaded fastening device 32 (e.g., a bolt 32 withexternal threads disposed on the shaft thereof). Specifically, the shaftof the bolt 32 passes through respective apertures in each of thecomponents 10, 20, and 30, and the bolt 32 is secured in place with anut 36 at the upper end thereof. Referring to the exploded view of FIG.9, it can be seen that the bolt 32 passes through the locking cap member38 beneath the tubular support member 30, and then through the lockrivet member 56 as the bolt 32 passes through tubular support member 30.On the top surface of the tubular support member 30, it can be seen thata lower push nut 34 circumscribes the bolt 32. As it proceeds upwardlythrough the clamp assembly 50, the bolt 32 then passes through a rivetnut 23 disposed in the bottom of the lower clamp member 20, and thenthrough an aperture in the bottom of the upper clamp member 10 until itreaches the upper nut 36. As best illustrated in FIGS. 5, 6, and 9, theupper and lower clamp members 10, 20 are spring-biased by spring member40. The spring member 40 is compressed between the bottom surface of theupper clamp member 10 and the upper rim of the rivet nut 23, which isdisposed in the aperture 21 in the base portion 22 of the lower clampmember 20 (see FIG. 10).

An illustrative upper clamp member 10 of the clamp assembly 50 isdepicted in FIG. 8. As shown in this figure, the upper clamp member 10generally includes a base portion 12, first and second opposed flangeportions 14 a, 14 b, and an upper ledge portion 17 that is disposedbetween, and is slightly recessed below, the opposed flange portions 14a, 14 b. The base portion 12 of the upper clamp member 10 is providedwith a fastener aperture 19 for receiving the bolt 32, while the upperledge portion 17 of the upper clamp member 10 is provided with a toolaperture 18 for accommodating the passage of a tool for tightening thenut 36 on the end of the bolt 32 (e.g., a socket wrench for tighteningthe nut 36). Also, as shown in FIG. 8, the first opposed flange portion14 a is provided with a set screw/set pin aperture 16 for accommodatinga set screw/set pin 52 that engages the top surface of the lower skirtmember 106. The vertical walls of the upper clamp member 10 that extendupwardly from the base portion 12 generally align with vertical walls oflower clamp member 20 illustrated in FIG. 10.

An illustrative lower clamp member 20 of the clamp assembly 50 isdepicted in FIG. 10. As shown in this figure, the lower clamp member 20generally includes a base portion 22, opposed wall portions 24 with amiddle ledge or shelf portion disposed therebetween, and opposed ledgesor wings 26, 28 extending outwardly from the outer sides of the walls24. The base portion 22 of the lower clamp member 20 is provided with anaperture 21 disposed therein for receiving the rivet nut 23, while themiddle ledge or shelf portion of the lower clamp member 20 is providedwith an aperture 25 for accommodating the passage of the bolt 32therethrough. Also, as shown in FIG. 10, the first opposed ledge or wing26 is provided with a groove 27 formed therein for receiving thedownturned bottom edge of the skirt mounting bracket 110 (see FIG. 19).The spaced-apart vertical walls 24 of the lower clamp member 20 thatextend upwardly from the base portion 22 generally align with verticalwalls of upper clamp member 10 illustrated in FIG. 8. The rivet nut 23that is received within the aperture 21 in the base portion 22 comprisesinternal threads for engaging the external threads of the bolt 32 thatcompresses the clamp assembly 50. As shown in FIG. 19, the PV modules114 rest on one or both of the generally horizontal ledges or wings 26,28. The vertical walls 24 keep the upper clamp member 10 in alignment(see FIG. 6), even when the same clamp is used as an end clamp.

With reference to FIGS. 5, 6, and 10, it can be seen that the secondopposed ledge or wing 28 is bent slightly upward or is tapered slightlyupward at an acute angle θ₁ (see FIG. 6). In the installed state (asillustrated in FIG. 25), the upwardly tapered ledge 28 of the lowerclamp member 20 extends uphill and slightly up and away from thebuilding roof 98 so as to act as a leaf spring that takes up thedifference in gap between the uphill clamp opening and the PV module 114thickness, thereby preventing the PV module 114 from rattling andallowing it to be secured into place. In some embodiments, this alsocreates enough pressure on the upper clamp lip (i.e., second opposedflange portion 14 b of upper clamp member 10) to enable a bonding pointto function. The second opposed ledge or wing 88 of the lower couplingmember 80, which will be described in detail hereinafter, is alsoprovided with a similar slight upward taper at an acute angle θ₂ (seeFIG. 14) to also act as a leaf spring that takes up the difference ingap between the uphill clamp opening and the PV module 114 thickness,thereby preventing the PV module 114 from rattling and allowing it to besecured into place. Advantageously, because the second opposed ledge orwing 28 (i.e., flange 28) of the lower clamp member 20 and secondopposed ledge or wing 88 (i.e., flange 88) of the lower coupling member80 are both provided with slight upward tapers (i.e., bowed upwardly),the lower clamp member 20 and lower coupling member 80 apply acompressive force against the PV module 114 when it is installedtherein. During the installation of each PV module 114, the PV module114 is initially disposed at an upward acute angle relative to its oneor more southern clamp assemblies 50 and coupling assemblies 60. Then,each PV module 114 is rotated down until it is generally parallel withthe roof surface. As each PV module 114 is rotated downwardly towardsthe roof surface, the edge portion of the uphill PV module 114 pressesdown on the upwardly tapered ledge(s) 28 of the lower clamp member(s) 20and the upwardly tapered ledge(s) 88 of the lower coupling member(s) 80,so as to apply a downward force on the upwardly tapered ledges 28 and88, thereby ensuring that the PV module 114 is securely engaged with thelower clamp member(s) 20 and lower coupling member(s) 80 and the PVmodule 114 is tightly held in place. In response to the downward forceapplied by the PV module 114, the upwardly tapered ledges 28 and 88elastically deform or yield in a spring-like manner. As a result of theleaf spring design of the upwardly tapered ledges 28 and 88, theinstaller is not required to reach down over the PV module 114 totighten the nuts 36 on its one or more southern clamp assemblies 50, orto tighten the bolts 90 on its one or more southern coupling assemblies60. An attempt by the installer to tighten the nuts 36 on the one ormore southern clamp assemblies 50, or to tighten the bolts 90 on the oneor more southern coupling assemblies 60, would not be safe, ergonomic,or efficient.

Advantageously, the adjustable clamp assembly 50 that includes the upperand lower clamp members 10, 20 allows the module support surfaceattachment device 100 to be attached to any photovoltaic module or panel114 of any thickness without requiring a custom profile. The adjustableclamp assembly 50 operates as a compression clamp, and may be attachedanywhere along any one of the four (4) peripheral edges of the PVmodules 114. The universal clamp design of the adjustable clampingassembly 50 advantageously eliminates the need for separate mid and endclamps.

In the illustrated embodiment, the threaded fastening device 32 (e.g., abolt 32) is capable of serving two important distinct functions relatedto the support surface attachment device 100. First, the threadedfastening device 32, together with the nut 36 and the rivet nut 23,secures the upper and lower clamp members 10, 20 in an engagedrelationship with one or more PV modules 114 (e.g., as shown in FIG.19). Secondly, the same threaded fastening device 32 also enables theheight of the one or more PV modules 114 that are securely held in aclamped fashion by the support surface attachment device 100 to beadjusted relative to the support surface (i.e., the roof 98). Inparticular, the innovative design of the components of clamp assembly 50make this dual functionality of the threaded fastening device 32possible. In particular, in order to prevent the undesirable rotation ofthe threaded fastening device 32 when the nut 36 is tightened during PVmodule securement, the bottom surface of the head 32 a of the threadedfastening device 32 is provided with an outer circumferential projection35 and a central projection 37 (see FIGS. 45 and 46) that engage withthe upper surface of the bottom wall 43 of the groove 48 in the lowersupport member 42 in an interference fit. As such, the bottom surface ofthe head 32 a of the threaded fastening device 32 torsionally interferesor “bites” into the upper surface of the bottom wall 43 of the groove 48so as to prevent the rotation of the threaded fastening device 32 whenthe nut 36 is being torqued. In addition, the interference between thebottom surface of the head 32 a of the threaded fastening device 32 andthe upper surface of the bottom wall 43 of the groove 48 of the lowersupport member 42 maintains the grounding current path of the supportsurface attachment device 100. Conversely, in order to prevent theundesirable rotation of the nut 36 when the height of the one or more PVmodules 114 are being adjusted by rotating the threaded fastening device32, the nut 36 is designed to engage with a sufficient frictional forceagainst the top surface of the base portion 12 of the upper clamp member10. Also, the rivet nut 23 is fixed in place relative to the lower clampmember 20 such that it does not rotate during the torqueing of thethreaded fastening device 32. In one exemplary embodiment, the nut 36 isprovided with a lower flange having a one-way serration pattern disposedon the bottom thereof that frictionally interferes or “bites” into thetop surface of the base portion 12 of the upper clamp member 10. Thus,when the threaded fastening device 32 is rotated in either a clockwisedirection or a counter-clockwise direction (e.g., by engaging a drill orwrench with the hexagonal recess 33 disposed in the top thereof—FIGS. 5and 9), the height of the one or more PV modules 114 are capable ofbeing adjusted without the loosening the clamp members 10, 20. Duringheight adjustment, the torque to turn the threaded fastening device 32has to be greater than the torque caused by the tightening of the nut 36so as to overcome the frictional engagement between the head 32 a of thethreaded fastening device 32 and the bottom wall 43 of the groove 48 ofthe lower support member 42. In addition, during height adjustment andafter the nut 36 has secured the clamp in place, the requisite torque toturn the threaded fastening device 32 by overcoming the threadresistance and the frictional resistance between the head 32 a and thelower support member 42 has to be less than the torsional strength ofthe threaded fastening device 32 (i.e., to avoid shearing the shaft ofthe threaded fastening device 32), and it has to be less than thetorsional strength of the drill bit or other type of tool that is usedto rotate the threaded fastening device 32). During the securement ofthe upper and lower clamp members 10, 20, the torque required to tightenthe nut 36 must be less than the resistance torque resulting from thefrictional engagement between the head 32 a and the lower support member42.

Now, turning to FIGS. 11-16 and 18, the components of the couplingdevices 60 of the PV module mounting system illustrated in FIG. 25 willbe described. Initially, referring to FIGS. 11, 14, and 18, it can beseen that the illustrative coupling device 60 of the photovoltaicmounting system generally comprises an upper coupling member 70 and alower coupling member 80. As shown in FIGS. 11 and 14, the uppercoupling member 70 is connected to the lower coupling member 80 by aplurality of threaded fastening devices 90 (e.g., two (2) spaced-apartbolts 90 with external threads disposed on the shafts thereof).Specifically, the shafts of the bolts 90 pass through respectiveapertures in each of the components 70, 80, and the bolts 90 are securedin place with respective rivet nuts 83 at the lower ends thereof (e.g.,see FIG. 14). Referring to the end view of FIG. 14 and the exploded viewof FIG. 18, it can be seen that the bolts 90 pass through respectiveapertures 71 in base portion 72 of the upper coupling member 70, andthen through respective apertures 85 in the middle ledge or shelfportion of the lower coupling member 80. The heads 92 of the bolts 90both rest on the top surface of the base portion 72 of the uppercoupling member 70, while the lower, opposite ends of the bolts 92 arethreadingly received by respective rivet nuts 83. As best illustrated inFIGS. 11 and 14, the upper and lower coupling members 70, 80 arespring-biased by spring members 94. The spring members 94 are compressedbetween the bottom surface of the upper coupling member 70 and the upperrims of respective rivet nuts 83, which are disposed in respectiveapertures in the base portion 82 of the lower coupling member 80.

An illustrative upper coupling member 70 of the coupling device 60 isdepicted in FIG. 15. As shown in this figure, the upper coupling member70 generally includes a base portion 72, first and second opposed flangeportions 74 a, 74 b, and an upper ledge portion 77 that is disposedbetween, and is slightly recessed below, the opposed flange portions 74a, 74 b. The base portion 72 of the upper coupling member 70 is providedwith spaced-apart fastener apertures 71 for receiving the bolts 90,while the upper ledge portion 77 of the upper coupling member 70 isprovided with tool apertures 75 for accommodating the passage of a toolfor tightening the heads 92 of the bolts 90 on the end of the bolts 90(e.g., a socket wrench for tightening the bolts 90). Also, as shown inFIG. 15, the second opposed flange portion 74 b is provided with a setscrew/set pin aperture 76 for accommodating a set screw/set pin 78 thatengages the top surface of the lower skirt member 106 or an upper skirtmember. The spaced-apart vertical walls of the upper coupling member 70that extend upwardly from the base portion 72 generally align with thevertical walls of lower clamp member 80 illustrated in FIG. 16. One orboth of the opposed flange portions 74 a, 74 b of the upper couplingmember 70 may be provided with a coin/catch that allows the user (i.e.,the installer) to slide the coupling device 60 onto the PV module 114without the coupling device 60 slipping off of the PV module 114 priorto it being torqued.

An illustrative lower coupling member 80 of the coupling device 60 isdepicted in FIG. 16. As shown in this figure, the lower coupling member80 generally includes a base portion 82, opposed wall portions 84 with amiddle ledge or shelf portion disposed therebetween, and opposed ledgesor wings 86, 88 extending outwardly from the outer sides of the walls84. The base portion 82 of the lower coupling member 80 is provided withlongitudinally spaced-apart apertures for receiving respective rivetnuts 83, while the middle ledge or shelf portion of the lower couplingmember 80 is provided with longitudinally spaced-apart apertures 85 foraccommodating the passage of respective bolts 90 therethrough. Also, asshown in FIG. 16, the first opposed ledge or wing 86 is provided with agroove 87 formed therein for receiving the downturned bottom edge of theskirt mounting bracket 110. The spaced-apart vertical walls 84 of thelower coupling member 80 that extend upwardly from the base portion 82generally align with the vertical walls of upper coupling member 70illustrated in FIG. 15. The rivet nuts 83 that are received withinrespective apertures in the base portion 82 of the lower coupling member80 each comprise internal threads for engaging the external threads ofrespective bolts 90 that compress the coupling device 60. Similar to theclamp assembly 50 shown in FIG. 19, the PV modules 114 rest on one orboth of the generally horizontal ledges or wings 86, 88 of the lowercoupling member 80. The vertical walls 84 keep the upper coupling member70 in alignment (see FIG. 14) even when the coupling device 60 is usedto couple the end portions of adjacent PV modules 114 in the same row.

Advantageously, the adjustable coupling device 60, which includes theupper and lower coupling members 70, 80, may be attached to anyphotovoltaic module or panel 114 of any thickness without requiring acustom profile. In other words, the coupling device 60 easily couples aplurality of off-the-shelf PV modules 114 without the need for a specialcustom profile. Like the clamp assembly 50, the adjustable couplingdevice 60 operates as a compression clamp, and may be attached anywherealong any one of the four (4) peripheral edges of the PV modules 114.The universal clamp design of the adjustable coupling device 60advantageously eliminates the need for separate mid and end clamps.

In one exemplary embodiment, the upper and lower coupling members 70, 80may be formed from aluminum, and the threaded fastening devices 90(e.g., bolts) may be formed from stainless steel. Also, in one or moreembodiments, the upper and lower coupling members 70, 80 may be combinedwith the threaded fastening device 32 and the upper support member 30 ofthe support surface attachment device 100 by first removing the upperand lower clamp members 10, 20 therefrom, and then attaching the upperand lower coupling members 70, 80 to the threaded fastening device 32.This combined assembly is particularly useful when the location of aclamp assembly 50 of the support surface attachment device 100 conflictswith the location of a coupling assembly 60 in photovoltaic arrayinstallation.

Now, turning to FIGS. 19-25, a skirt member 106 of the photovoltaicmounting system will be described. Initially, referring to FIG. 25, itcan be seen that the skirt member 106 is located on the southernmostedge of the array of PV modules 114. The skirt member 106 is supportedby the spaced-apart support surface attachment devices 100. Inparticular, as shown in FIGS. 19 and 20, the skirt member 106 and itsassociated mounting bracket 110 is sandwiched between the upper clampmember 10 and the lower clamp member 20 of the clamp assembly 50 of thesupport surface attachment device 100. In other words, the skirt member106 and its associated mounting bracket 110 are clampingly engaged bythe upper clamp member 10 and the lower clamp member 20. Also, asexplained above, the downturned edge of the skirt mounting bracket 110is received within the groove 27 that is formed within the first opposedledge or wing 26 of the lower clamp member 20.

Next, referring to FIGS. 21-24, the engagement between the skirt member106 and the skirt mounting bracket 110 will be explained. As shown inFIG. 23, a backside of the diagonal skirt member 106 comprises aplurality of teeth-like projections or protrusions 108. Similarly, asbest depicted in FIG. 24, the front side of the skirt mounting bracket110 comprises a plurality of teeth-like projections or protrusions 112.With reference to FIGS. 21 and 22, it can be seen that at least some ofthe teeth-like projections or protrusions 108 of the diagonal skirtmember 106 matingly engage with at least some of the teeth-likeprojections or protrusions 112 on the skirt mounting bracket 110. Thisengagement between the teeth-like projections 108, 112 enables the skirtmounting bracket 110 to support the skirt member 106 on the clampassembly 50. Advantageously, the teeth-like projections or protrusions108, 112 on the skirt member 106 and the skirt mounting bracket 110,respectively, allows the skirt member 106 to be mounted at variousheights relative to the skirt mounting bracket 110 so that the skirtassembly 106, 110 is capable of matching the height of any PV module114. This is important because then the skirt assembly 106, 110 sets thegap size of the clamp assembly 50 and the coupling assembly 60 on thesouth row of the PV array to accept the first row of PV modules 114.

As shown in FIG. 25, the skirt member 106 covers the exposed downhilledge of the array of PV modules 114 (only one skirt member 106 is shownin FIG. 25). Because the skirt member(s) 106 closes out the south row ofPV modules 114, it improves the aesthetics of the completed photovoltaicarray. No clamps or hardware is seen from ground. Airflow around thearray is permitted. In one exemplary embodiment, the skirt member 106may be formed from aluminum. In another exemplary embodiment, the skirtmember 106 may be formed from a suitable polymer.

Referring to FIGS. 26 and 27, an illustrative bracket assembly 120 ofthe photovoltaic mounting system will be described. As explained above,one or more bracket assemblies 120 may be used for securing one or morerespective electrical assemblies (e.g., one or more micro-inverters) tothe underside of one or more PV modules 114. As shown in FIGS. 26 and27, the bracket assembly 120 generally comprises an upper bracket member124 that is connected to a lower bracket member 130 by means of athreaded fastening device 134 (e.g., a bolt 134 with external threadsdisposed on the shaft thereof). Specifically, the shaft of the bolt 134passes through respective apertures in each of the components 124, 130,and the bolt 134 is secured in place with a nut 122 at the upper endthereof. Referring to FIGS. 26 and 27, it can be seen that the bolt 134passes through a rivet nut 132 disposed in the bottom of the lowerbracket member 130, then through an aperture located in the ledge orshelf portion of the lower bracket member 130, and finally through anaperture in the bottom of the upper bracket member 124 until it reachesthe upper nut 122. Also, as illustrated in FIGS. 26 and 27, the upperand lower bracket members 124, 130 are spring-biased by spring member128. The spring member 128 is compressed between the bottom surface ofthe upper bracket member 124 and the upper rim of the rivet nut 132,which is disposed in the aperture in the base portion 22 of the lowerbracket member 130. The bracket assembly 120 clamps to a PV module 114by respectively engaging the opposed top and bottom surfaces of the PVmodule 114 with the flange portion of the upper bracket member 124 andthe ledge or wing portion of the lower bracket member 130. As best shownin FIG. 27, one of the opposed flange portions of the upper bracketmember 124 is provided with a set screw/set pin 126 for engaging the topsurface of the PV module 114 to which it is attached. The electricalassembly (e.g., a micro-inverter) that is supported by the bracketassembly 120 typically comprises a notch that engages the bolt 134 nearthe head end thereof (e.g., in the gap between the bolt head and thebottom surface of the lower bracket member 130 in FIG. 27).

Next, a description of the manner in which the support surfaceattachment devices 100 of the mounting system are installed on a roofwill be provided. Initially, referring to FIGS. 1-4, the lower supportmember 42 and flashing member 96 of each support surface attachmentdevice 100 is secured to the building rooftop 98 using its respectivestructural mounting screw 102. Then, the clamp assemblies 50 areattached in a staged fashion to their respective lower support members42. Initially, each clamp assembly 50 is installed in the 9 o'clockposition on its respective lower support member 42 (see FIG. 1). Then,the upper tubular support member 30 of each clamp assembly 50, whichoperates as a handle, is turned approximately 90 degrees clockwise by auser thereof (i.e., a PV system installer) so that each clamp assembly50 is locked in place relative to its respective lower support member42. As the upper tubular support member 30 is turned by a user, theouter circumferential projection 35 and the central projection 37 of thehead 32 a of the threaded fastening device 32 “bite” into the lowersupport member 42 so as to prevent the clamp assembly 50 from turningwhile the upper tubular support member 30 is being rotated approximately90 degrees. The interference engagement between the head 32 a of thethreaded fastening device 32 and the lower support member 42 alsoprevents the clamp assembly 50 from drifting from its intended fixationlocation as the upper tubular support member 30 is rotated approximately90 degrees (i.e., it prevents north or south drifting of the clampassembly 50). Once each clamp assembly 50 is locked in place, it is in agenerally 12 o'clock position on its respective lower support member 42(see FIG. 2). An approximate height of the PV modules 114 relative tothe support surface (e.g., roof) may be achieved by rotating thesubassembly comprising the upper clamp member 10, lower clamp member 20,and the rivet nut 23 relative to the upper tubular support member 30 ofthe support surface attachment device 100. Height adjustment of the PVmodules 114 may be achieved by rotating the threaded fastening device 32(e.g., by using the hexagonal recess 33 disposed therein—FIGS. 5 and 9)relative to the nut 36, upper clamp member 10, lower clamp member 20,rivet nut 23, and upper support member 30.

A second illustrative embodiment of a support surface attachment deviceis seen generally at 200 in FIGS. 28-33. Referring to these figures, itcan be seen that, in some respects, the second illustrative embodimentis similar to that of the first embodiment of the support surfaceattachment device 100. Moreover, some elements are common to both suchembodiments. For the sake of brevity, the elements that the secondembodiment of the support surface attachment device has in common withthe first embodiment will not be discussed in detail because thesecomponents have already been described above.

In the second illustrative embodiment, as shown in FIGS. 28-33, thesupport surface attachment device 200 generally comprises a disc member236 configured to be attached to a support surface (e.g., the buildingrooftop 98 of FIG. 25), a clamp assembly 202, 208 configured to engageone or more PV modules 114, and a flashing member 254 for preventingleaks in the building roof 98. The disc member 236 is capable of beingrotated about the structural mounting screw 232 so as to permit theclamp assembly 202, 208 to be flexibly positioned on the building roof98. Because the clamp assembly 202, 208 can be positioned anywhere aboutthe circumference of the disc member 236 by the rotation of the discmember 236 about the structural mounting screw 232, the necessarymounting location of the PV modules 114 can be easily accommodated afterthe disc member 236 and the flashing member 254 have been attached to aroof rafter 116 by the structural mounting screw 232. As such, it is notnecessary for the base assembly of the support surface attachment device200, which comprises the disc member 236 and the flashing member 254, tobe precisely located along the length of the roof rafter 116 because thedisc member 236 described herein advantageously affords generousadjustability in the south-north installation direction and/or east-westinstallation direction. Also, the support surface attachment devices 200can also be flexibly located in the east-west direction on the buildingrooftop 98 such that they correspond with the spacing of the roofrafters 116 because the support surface attachment devices 200 can bemounted virtually anywhere along the length (i.e., east-west direction)of the PV modules 114.

Now, referring primarily to FIGS. 34-39, the disc member 236 of thesupport surface attachment device 200 will be described. As shown inthese figures, the disc member 236 generally comprises a dome-shapedbody portion 238 and a conical projection 240 that extends upwardly fromthe dome-shaped body portion 238 in a generally vertical direction. Asbest shown in FIGS. 34 and 35, the conical projection 240 is disposedproximate to an outer periphery of the dome-shaped body portion 238 ofthe disc member 236. The dome-shaped body portion 238 of the disc member236 comprises a centrally disposed aperture 244 for receiving structuralmounting screw 232. As mentioned above, during the installation of thesupport surface attachment device 200 on a roof, the disc member 236 iscapable of being rotated about the structural mounting screw 232 so asto allow the flexible positioning of the clamp assembly 202, 208. Inorder to prevent precipitation (i.e., rain water) from entering theaperture 244, the central aperture 244 is surrounded by a conical wall246. In FIGS. 28-32, it can be seen that, in an assembled state, acone-shaped sealing washer 234 is sandwiched between the head of thestructural mounting screw 232 and the conical wall 246 of the discmember 236 so as to further prevent precipitation from entering aperture244.

Turning again to FIGS. 34-39, it can be seen that the dome-shaped bodyportion 238 of the disc member 236 further includes a peripheral flangeportion 242 disposed about its outer periphery. As most clearlyillustrated in FIGS. 38 and 39, the peripheral flange portion 242 of thedisc member 236 comprises a plurality of downwardly extendingprojections 243 spaced apart along the annular bottom surface thereof.In addition, as shown in FIGS. 36 and 37, the bottom surface of thedome-shaped body portion 238 of the disc member 236 may be provided witha plurality of radially-extending ribs 250 that are circumferentiallyspaced apart about the disc member 236 so as to increase the structuralrigidity and durability of the disc member 236. Also, in the bottom viewof FIG. 36, it can be seen that the disc member 236 may also include acircumferentially-extending rib 252 circumscribing the central aperture244 so as to further enhance the structural rigidity and durability ofthe disc member 236. While a single circumferentially-extending rib 252is shown in the illustrative embodiment of FIG. 36, it is to beunderstood that, in other embodiments, the disc member 236 may beprovided with a plurality of radially spaced-apart ribs 252 that areconcentrically arranged with respect to one another for added strength.

With reference primarily to FIGS. 34, 35, and 38, the conical projection240 of the disc member 236 will be described in more detail. As shown inthese figures, the conical projection 240 is disposed on a side of thedome-shaped body portion 238 and comprises an aperture 248 disposed inthe center thereof for receiving the threaded fastener member 228 (e.g.,bolt 228) that adjustably connects the clamp assembly 202, 208 to thebase assembly 236, 254 of the support surface attachment device 200. Aswill be described hereinafter, the threaded fastener member 228 can berotated so as to adjust the vertical position or elevation of the clampassembly 202, 208 relative to the base assembly 236, 254. The aperture248 of the conical projection 240 is provided with a plurality ofinternal threads that threadingly engage with the plurality of externalthreads on the threaded fastener member 228. In one exemplaryembodiment, the disc member 236 may be formed from diecast metal, thestructural mounting screw 232 may be formed from stainless steel, andthe cone-shaped sealing washer 234 may be formed from ethylene propylenediene monomer (EPDM).

Next, referring to FIGS. 40-44, the plate-like flashing member 254 ofthe support surface attachment device 200 will be explained. Asdescribed above for the flashing member 96, the flashing member 254helps to maintain the integrity of the building roof 98 by preventingroof leaks. In FIGS. 40-44, it can be seen that the flashing member 254generally comprises a generally planar body portion 256 and a conicalprojection 258 that extends upwardly from the generally planar bodyportion 256 in a generally vertical direction. As best shown in the topview of FIG. 41, the conical projection 258 is offset with respect tothe center of the generally planar body portion 256 (i.e., the conicalprojection 258 is disposed to the side of the central point of thegenerally planar body portion 256). In FIGS. 40-44, it can be seen thatconical projection 258 is provided with an annular base portion 260disposed around the bottom periphery thereof. The conical projection 258further includes a centrally disposed aperture 262 for receiving thestructural mounting screw 232 therein. Advantageously, the raised natureof the conical projection 258 above the remainder of the generallyplanar body portion 256 of the flashing member 254 substantiallyprevents any precipitation (i.e., rain water) from entering thestructure of the building roof 98 through the fastener aperture 262. Inthe assembled state of the support surface attachment device 200, inorder to further prevent any leaks through the aperture 262 of theflashing member 254, a cone-shaped grommet 264 (see FIG. 33) is providedon the top of the conical projection 258 of the flashing member 254. Thecone-shaped grommet 264 is sandwiched between the conical projection 258of the flashing member 254 and the bottom surface of the conical wall246 surrounding the central aperture 244 of the disc member 236 when thedisc member 236 is disposed on top of the flashing member 254 in theassembled state of the support surface attachment device 200. In oneexemplary embodiment, the flashing member 254 may be formed from stampedmetal, and the cone-shaped grommet 264 may be formed from ethylenepropylene diene monomer (EPDM).

Advantageously, the design of the flashing member 254 illustrated inFIGS. 40-44 results in superior waterproofing because its water seal islocated approximately one (1) inch above the roof surface (i.e., at thetip of the conical projection 258) so that the integrity of the flashingwaterproofing is maintained even if the grommet 264 would fail. Also,because the flashing member 254 may be formed by stamping, itsmanufacturing costs are inexpensive. In addition, the configuration ofthe flashing member 254 allows adjacent flashing members 254 to bereadily stacked for compact shipping.

Now, with particular reference to FIGS. 28-33, the clamp assembly 202,208 of the support surface attachment device 200 will be explained. Asshown in these figures, the clamp assembly generally comprises an upperclamp member 202, a lower clamp member 208, and a threaded fastenermember 228 that adjustably connects the clamp assembly to the baseassembly 236, 256. As best shown in FIGS. 28, 31, and 33, the upperclamp member 202 is connected to the lower clamp member 208 by athreaded fastening member 226 (e.g., a bolt 226 with external threadsdisposed on the shaft thereof). Specifically, the shaft of the bolt 226passes through apertures in each of the clamping components 202, 208,and the bolt 226 is secured in place with a rivet nut at the bottom endthereof. Referring to the partially exploded view of FIG. 33, it can beseen that the bolt 226 passes through upper and lower apertures in theupper clamp member 202, and then through the fastener aperture 212 ofthe lower clamp member 208 until it reaches the rivet nut at the bottomend of the bolt 226. When it is desired to secure the clamp assembly202, 208 to one or more photovoltaic modules, a tool (e.g., ascrewdriver or a battery-powered drill with the appropriate bit) isinserted into the hexagonal recess 227 in the top end of the bolt 226and the bolt 226 is tightened until the one or more frames of the one ormore photovoltaic modules are securely clamped between the upper andlower clamp members 202, 208.

An illustrative upper clamp member 202 of the clamp assembly 202, 208 isdepicted in FIG. 28-33. With combined reference to FIGS. 28 and 33, itcan be seen that the upper clamp member 202 generally includes a baseportion 204, first and second opposed flange portions 206 a, 206 b, andan upper planar portion that is disposed between the opposed flangeportions 206 a, 206 b. Both the base portion 204 and upper planarportion of the upper clamp member 202 are provided with a fastenerapertures disposed therein for receiving the shaft of the bolt 226. Thevertical walls of the upper clamp member 202 that extend upwardly fromthe base portion 204 generally align with the upright wall portion 218of lower clamp member 208 that will be described hereinafter. In manyrespects, the upper clamp member 202 of the second embodiment is similarto that of the upper clamp member 10 of the first embodiment describedabove.

An illustrative lower clamp member 208 of the clamp assembly 202, 208 isalso depicted in FIGS. 28-33. With initial reference to FIG. 33, it canbe seen that the lower clamp member 208 generally includes a baseportion 210, an upright wall portion 218, and opposed ledges or wings220, 224 extending outwardly from the outer sides of the base portion210. The upper shelf of the base portion 210 of the lower clamp member208 is provided with first and second apertures 212, 214 disposedtherein (see FIG. 28) for receiving the threaded fastener member 226 andthe rivet nut 216, respectively. Also, as shown in FIGS. 31 and 33, thefirst opposed ledge or wing 220 is provided with a groove 222 formedtherein for receiving the downturned bottom edge of the skirt mountingbracket 110 (see FIG. 19). The upright wall portion 218 of the lowerclamp member 208 that extends upwardly from the base portion 210generally aligns with vertical walls of upper clamp member 202 (seeFIGS. 31 and 33). The rivet nut 216 that is received within the aperture214 in the base portion 210 comprises internal threads for engaging theexternal threads of the threaded fastener member 228 (e.g., threadedstud 228) that adjusts the height of the clamp assembly 202, 208relative to the base assembly 236, 254. When it is desired to adjust theheight of the clamp assembly 202, 208 relative to the base assembly 236,254 (e.g., so as to level the PV modules 114 in the array), a tool(e.g., a screwdriver or a battery-powered drill with the appropriatebit) is inserted into the hexagonal recess 230 in the top end of thestud 228 and the stud 228 is rotated either clockwise orcounter-clockwise to either raise or lower the clamp assembly 202, 208relative to the base assembly 236, 254. Similar to that described abovefor the clamp assembly 50 of the first embodiment (e.g., see FIG. 19),the PV modules 114 rest on one or both of the generally horizontalledges or wings 220, 224 of the lower clamp member 208 of the clampassembly 202, 208. The upright wall portion 218 of the lower clampmember 208 helps to keep the upper clamp member 202 in alignment (seeFIG. 33), even when the same clamp is used as an end clamp. Except forhaving a single upright wall portion 218 rather than two spaced-apartvertical walls, the lower clamp member 208 of the second embodiment issimilar in many respects to that of the lower clamp member 20 of thefirst embodiment described above.

Advantageously, the support surface attachment device 200 describedabove in conjunction with the second embodiment is easy to install, shipto the jobsite, aesthetically pleasing, cost effective to manufacture,and results in a substantial reduction of material usage and part count.The disc member 236, which may be die-cast, allows relatively highmanufacturing tolerances to be used, thereby resulting in substantialreduction in fabrication costs. Also, the apertures in the upper andlower clamp members 202, 208 described above may be punched duringmanufacturing, and computer numerical control (CNC) machining is notrequired. The support surface attachment device 200 results in aphotovoltaic array with superior aesthetics because the spacing betweennorth-south modules is capable of being reduced from approximately 1.25inches down to approximately 0.625 inches. In addition, the installationof the support surface attachment devices 200 on the building roof isvery quick because only a single tool (e.g., a screwdriver or abattery-powered drill with the appropriate bit) is needed for the entireinstallation.

It is readily apparent that the aforedescribed photovoltaic mountingsystem offers numerous advantages. First, the photovoltaic mountingsystem described herein, which generally comprises one or more couplingdevices 60 and one or more support surface attachment devices 100, 200,attaches to rafters or roof supporting members, and avoids using railsor struts, and is universal. In other words, the photovoltaic mountingsystem provides an easy way to install off-the-shelf photovoltaicmodules or panels with support surface attachment devices 100, 200 thatanchor into roof rafters or trusses, without the need for rails.Secondly, the photovoltaic mounting system mounts to any photovoltaicmodule on the market, giving installers the flexibility to choose themodule of their choice, rather than being required to buy a module witha custom profile rail to accommodate the mounting system. In addition,the photovoltaic mounting system described herein includes integratedgrounding means so that wired PV module grounding or bonding is notrequired (i.e., the metallic constituent components of the couplingdevices 60 and the support surface attachment devices 100, 200 formconductive current paths for integrated grounding or bonding). Finally,the photovoltaic mounting system described herein provides installerswith easy and efficient means by which the photovoltaic modules in thearray can be leveled in the field.

Any of the features or attributes of the above described embodiments andvariations can be used in combination with any of the other features andattributes of the above described embodiments and variations as desired.

Although the invention has been shown and described with respect to acertain embodiment or embodiments, it is apparent that this inventioncan be embodied in many different forms and that many othermodifications and variations are possible without departing from thespirit and scope of this invention.

Moreover, while exemplary embodiments have been described herein, one ofordinary skill in the art will readily appreciate that the exemplaryembodiments set forth above are merely illustrative in nature and shouldnot be construed as to limit the claims in any manner. Rather, the scopeof the invention is defined only by the appended claims and theirequivalents, and not, by the preceding description.

The invention claimed is:
 1. A support surface attachment device, saidsupport surface attachment device configured to attach one or morephotovoltaic modules to a support surface, said support surfaceattachment device comprising: a rotatable base member, said rotatablebase member being pivotal about a central rotational axis, saidrotatable base member configured to be attached to a support surface,and said rotatable base member including spaced-apart walls with opposedinwardly protruding portions defining a slot for receiving a securementmember; an upper support member, said upper support member coupled tosaid rotatable base member by said securement member; and a clampassembly configured to engage one or more photovoltaic modules, saidclamp assembly coupled to said rotatable base member and said uppersupport member, a portion of said upper support member disposed betweensaid clamp assembly and said rotatable base member; wherein said clampassembly and said upper support member are capable of being selectivelypositioned along a circumferential path of said rotatable base memberprior to said rotatable base member being fixed in place relative tosaid support surface so as to permit adjustability when said one or morephotovoltaic modules are being attached to said support surface.
 2. Thesupport surface attachment device according to claim 1, wherein saidclamp assembly of said support surface attachment device comprises alower clamp member and an upper clamp member, said upper clamp memberconnected to said lower clamp member by a first threaded fasteningmember.
 3. The support surface attachment device according to claim 2,wherein said lower clamp member of said clamp assembly comprises a lowerledge extending from an outer side of said lower clamp member, and saidupper clamp member comprises an upper flange portion, said lower ledgeand said upper flange portion together defining a clamp recess.
 4. Thesupport surface attachment device according to claim 3, wherein saidlower clamp member further comprises at least one vertical wallextending upwardly from said lower ledge, and said upper clamp memberfurther comprises a base portion extending downwardly from said upperflange portion, said base portion of said upper clamp member overlappingsaid at least one vertical wall of said lower clamp member.
 5. Thesupport surface attachment device according to claim 4, wherein said atleast one vertical wall of said lower clamp member comprises a pair ofvertical walls extending upwardly from said lower ledge, said baseportion of said upper clamp member being received within said pair ofvertical walls of said lower clamp member.
 6. The support surfaceattachment device according to claim 2, further comprising a secondthreaded fastening member, said second threaded fastening membercoupling said clamp assembly to said rotatable base member.
 7. Thesupport surface attachment device according to claim 1, furthercomprising a flashing member having a fastener aperture configured toreceive a fastener for attaching said rotatable base member and saidflashing member to said support surface, said fastener aperture beingdisposed through a raised portion of said flashing member so that wateris prevented from passing through said fastener aperture.
 8. A supportsurface attachment device, said support surface attachment deviceconfigured to attach one or more photovoltaic modules to a supportsurface, said support surface attachment device comprising: a rotatablebase member, said rotatable base member being pivotal about a centralrotational axis, said rotatable base member configured to be attached toa support surface; an upper support member, said upper support membercoupled to said rotatable base member; and a clamp assembly configuredto engage one or more photovoltaic modules, said clamp assembly coupledto said rotatable base member and said upper support member, a portionof said upper support member disposed between said clamp assembly andsaid rotatable base member, and said clamp assembly including a lowerclamp member and an upper clamp member, said lower clamp member of saidclamp assembly including a lower ledge extending from an outer side ofsaid lower clamp member, and said upper clamp member including an upperflange portion, said lower ledge and said upper flange portion togetherdefining a clamp recess, said lower clamp member further including atleast one vertical wall extending upwardly from said lower ledge, andsaid upper clamp member further including a base portion extendingdownwardly from said upper flange portion, said base portion of saidupper clamp member overlapping said at least one vertical wall of saidlower clamp member; wherein said clamp assembly and said upper supportmember are capable of being selectively positioned along acircumferential path of said rotatable base member prior to saidrotatable base member being fixed in place relative to said supportsurface so as to permit adjustability when said one or more photovoltaicmodules are being attached to said support surface.
 9. The supportsurface attachment device according to claim 8, wherein said upper clampmember is connected to said lower clamp member by a threaded fasteningmember.
 10. The support surface attachment device according to claim 8,wherein said rotatable base member is an elongate member withspaced-apart walls.
 11. The support surface attachment device accordingto claim 8, further comprising a flashing member having a fasteneraperture configured to receive a fastener for attaching said rotatablebase member and said flashing member to said support surface.
 12. Asupport surface attachment device, said support surface attachmentdevice configured to attach one or more photovoltaic modules to asupport surface, said support surface attachment device comprising: arotatable base member, said rotatable base member being pivotal about acentral rotational axis, said rotatable base member configured to beattached to a support surface, and said rotatable base member includingspaced-apart walls with opposed inwardly protruding portions defining aslot for receiving a securement member; an upper support member, saidupper support member coupled to said rotatable base member by saidsecurement member; and a clamp assembly configured to engage one or morephotovoltaic modules, said clamp assembly coupled to said rotatable basemember and said upper support member, a portion of said upper supportmember disposed between said clamp assembly and said rotatable basemember, and said clamp assembly including a lower clamp member and anupper clamp member, said lower clamp member of said clamp assemblyincluding a lower ledge extending from an outer side of said lower clampmember, and said upper clamp member including an upper flange portion,said lower ledge and said upper flange portion together defining a clamprecess, said lower clamp member further including at least one verticalwall extending upwardly from said lower ledge, and said upper clampmember further including a base portion extending downwardly from saidupper flange portion, said base portion of said upper clamp memberoverlapping said at least one vertical wall of said lower clamp member;wherein said clamp assembly and said upper support member are capable ofbeing selectively positioned along a circumferential path of saidrotatable base member prior to said rotatable base member being fixed inplace relative to said support surface so as to permit adjustabilitywhen said one or more photovoltaic modules are being attached to saidsupport surface.
 13. The support surface attachment device according toclaim 12, wherein said upper clamp member is connected to said lowerclamp member by a threaded fastening member.
 14. The support surfaceattachment device according to claim 12, further comprising a flashingmember having a fastener aperture configured to receive a fastener forattaching said rotatable base member and said flashing member to saidsupport surface.